Guest 16202 User manual

R
Intelligent Charging System Series
OWNER’S MANUAL
ON BOARD BATTERY CHAR ERS
Models Amperage No. Of Banks Volts
16061 6 Amps 1 Bank 12
16102 6,6 Amps 2 Banks 12 or 24
16153 6,6,6 Amps 3 Banks 12 or 24 or 36
16202 10,10 Amps 2 Banks 12 or 24
IMPORTANT NOTICE
This manual contains important safety and operating instructions for the charger. ead
the entire manual before using. Also read all instructions and cautions for and on the
charger, batteries and equipment in the vicinity of the batteries.
SAVE THESE INSTRUCTIONS

2
IMPORTANT SAFETY INSTRUCTIONS
This manual contains important safety and operating instructions for the charger. ead
the entire manual before using. Also read all instructions and cautions for the charger,
batteries and equipment in the vicinity of the batteries.
WARNINGS
THIS CHAR ER SHOULD BE USED TO CHAR E ONLY FLOODED LEAD ACID,
A M OR EL CELL TYPE BATTERIES. USE ON OTHER BATTERY TYPES MAY
CAUSE THE BATTERY TO EXPLODE AND CAUSE PERSONAL INJURY.
RISK OF EXPLOSIVE ASES! WORKIN IN THE VICINITY OF LEAD ACID
BATTERIES IS DAN EROUS. BATTERIES ENERATE EXPLOSIVE ASES
DURIN NORMAL OPERATION. THEREFORE IT IS OF THE UTMOST
IMPORTANCE THAT EACH TIME BEFORE USIN YOUR CHAR ER YOU FOLLOW
THE INSTRUCTIONS EXACTLY.
AC Connection and rounding Precautions
DANGER
DO NOT OPERATE THIS CHAR ER WITH A TWO BLADED ADAPTER PLU OR
EXTENSION CORD. DOIN SO CAN RESULT IN SERIOUS PERSONAL INJURY.
AFTER SECURIN THE BATTERY CONNECTIONS, PLU THE AC LINE CORD
INTO AN AVAILABLE AC OUTLET THAT IS PROTECTED BY A ROUND FAULT
CIRCUIT INTERRUPTER ( FCI) BREAKER.
CAUTION
TO REDUCE THE RISK OF SHOCK, CONNECT ONLY TO A PROPERLY ROUNDED
OUTLET
NOTE: AC Line Cord color-coding is EU style. Line = Brown, Neutral = Blue, Ground =
Green

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Table of Contents Page
IMPORTANT SAFETY INSTRUCTIONS 2
INTRODUCIN THE CHAR ER 4
Personal Safety Precautions 4
Preparing to Charge Precautions 5
INSTALLIN THE CHAR ER 5 – 18
Choosing a Mounting Location 5
Mounting The Charger 6
Making DC Connections 6
Setting Up The Battery Chemistry 6
Making AC Connection 7
DC Output Wiring Configurations 7 - 18
OPERATION OF THE CHAR ER 19 - 20
LED Function Chart 19
Charger Algorithm Chart 20
Battery Fault Indication 20
TROUBLESHOOTIN 21 – 22
MAINTAININ THE CHAR ER 22
SPECIFICATIONS 23
ADDITIONAL FEATURES 24
EMC NOTICE 24
LIMITED WARRANTY 25

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INTRODUCIN THE CHAR ER
The Guest models 16061, 16102, 16153, 16202 are microprocessor controlled, 3-stage
electronic switching battery chargers. Each output produces 12 Volts DC at either a full 6
Amps or 10 Amps (model specific), while using much less AC current than other
chargers. Pre-wired on the AC input and DC outputs, these units feature a push button
interface that allows the user to configure individual outputs for different battery chemistry
types. One tri-color LED per output will indicate which battery chemistry type has been
selected. Tri-color LED readout indicates state of charge for each bank. Unlike
automotive “trickle” chargers, the 16061, 16102, 16153, 16202 will not boil off the
electrolytes in properly installed and maintained batteries. When the charger is
connected to your batteries and plugged into a standard 115 Volt / 60 Hz AC outlet, the
tri-color LED (red, blue, green) mounted on the face of the charger will let you know the
unit is recharging and maintaining your batteries. This sophisticated device is ideal for
recharging and maintaining the 12VDC batteries in your boat, electric vehicle, ATV,
snowmobile and motorcycle.
Personal Safety Precautions
Adhere to the following personal safety precautions when installing or working with the
chargers:
1. Someone should be within voice range or close enough to come to your aid when you
work near a lead-acid battery.
2. Have plenty of fresh water and soap nearby in case battery acid contacts skin,
clothing, or eyes.
3. Wear complete eye protection and clothing protection. Avoid touching eyes while
working near a battery.
4. If battery acid contacts skin or clothing, wash them immediately with soap and water.
If acid enters the eye, flood the eye with cold, running water for at least ten minutes
and get medical attention.
5. Never smoke or allow an open flame in the vicinity of the battery.
6. Do not drop a metal tool onto the battery. It may short-circuit the battery, spark and
may cause an explosion.
7. emove all personal metal items such as rings, bracelets, necklaces, and watches
when working near a lead-acid battery. A battery can produce short circuit currents
high enough to weld a ring or the like to metal, causing a severe burn.

5
Preparing to Charge Precautions
Before charging a battery with the charger, read the following precautions:
1. Do NOT operate the charger if the cable or an LED indicator is damaged.
2. Make sure all accessories on the product you are charging are OFF.
3. If the battery or batteries must be removed from the product, always remove the
grounded terminal from the battery first.
4. Be sure the area around the battery is well ventilated while the battery is being
charged. Gas can be forcefully blown away using a piece of cardboard or other non-
metallic material as a “hand fan”.
5. Clean battery terminals. Be careful to keep corrosion from coming into contact with
eyes.
6. Add distilled water in each cell until battery acid reaches levels specified by the
battery manufacturer, if applicable. Do not overfill. Check water levels frequently.
For a battery without cell caps, carefully follow the manufacturer’s recharging
instructions.
7. Never allow the charger battery connection ring terminals to touch each other.
8. NEVER charge a frozen battery.
INSTALLIN THE CHAR ER
Note: The initial installation consists of (a) Choosing a mounting location, (b) mounting
the charger, (c) making the DC connections, (d) selecting the appropriate battery
chemistry, (e) making the AC connections to a receptacle that is protected by a GFCI
breaker.
Choosing a Mounting Location
The charger should have at least eight inches of unobstructed area on all sides of the
unit for effective cooling. The case of this charger may become warm during operation.
For optimum performance, mount the charger in the vertical position (cables on the
bottom), this will improve the convection cooling (airflow over the back of the charger).
Mounting on its side or on a horizontal surface may cause the charger to slightly reduce
amperage output due to the thermal protection built in. Do not install the charger on
carpeted, upholstered, or varnished surfaces.

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Mounting the Charger
1. For 16061 use corrosion resistant #10 bolts, backed by a flat washer, and secured to
the mounting surface with a split-ring lock washer.
For the 16102, 16153 and 16202 use corrosion resistant ¼” bolts, backed by a flat
washer, and secured to the mounting surface with a split-ring lock washer.
2. Hold the charger to the mounting surface and mark the holes.
3. emove the charger and drill the mounting holes.
4. Align the charger and assemble the mounting hardware. Secure.
Making the DC Connections
Check polarity of the battery posts. The POSITIVE (POS., P, +) battery post usually has
a larger diameter than the NEGATIVE (NEG., N, -) post. Connect ed charger output
wire to POSITIVE post, Black charger wire to NEGATIVE. See below diagrams for more
details.
Setting Up the Battery Chemistry
Note: The battery chemistry needs to be set for each individual battery bank or charger
output.
The battery chemistry indicators are defined as follows:
Flooded Lead Acid (FLA) and AGM Battery Mode ed LED
Safe Mode Blue LED
Gel Battery Mode Green LED
After you connect the DC cables of the charger to the batteries, the battery chemistry
selection LED will illuminate (Safe Mode). At this point, you can toggle thru the different
battery chemistry selections by pressing the pushbutton on the membrane panel for each
specific output. Once AC is plugged in, this setting will be set by the micro into AM and
it will remember this setting until you interrupt both the battery power and AC power to
the charger.
The battery chemistry selection LED will turn OFF 10 minutes after the batteries are first
connected; this is called “sleep mode”. To recover from “sleep mode” press the battery
chemistry selection button, this will turn ON the battery chemistry selection LED as long
as AC power has not yet been applied.
The battery chemistry select LED will turn ON once AC has been applied to the charger
and turn OFF 10 minutes after AC has been disconnected.
If you do not know what type of battery you have, please choose the safe mode
algorithm, which was developed for an unknown battery chemistry or application
requirement.

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Making AC Connection
After setting your battery chemistry selections for each output, connect the AC plug into
an AC receptacle, which is protected by a Ground Fault Circuit Interrupter (GFCI)
breaker.
DC Output Wiring Configurations
This section shows possible DC wiring configurations for the following charger models:
16061, 16102, 16153, and 16202.
Diagram 1 – 16061 in a single Independent Output configuration
6 Amp
Output 1

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Diagram 2 – 16102 in a dual Independent Output configuration
6 Amp
Output 1
Engine
Start or
Trolling
6 Amp
Output 2
Model12 Amp
16102(6/6)
SA F E M O D E

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Diagram 3 – 16102 in a 24VDC, 6 Amp configuration
6 Amp
Output 1
Engine
Start or
Trolling
6 Amp
Output 2
Model12 Amp
16102(6/6)
SA F E M O D E

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Diagram 4 – 16102 in a 12VDC, 12Amp configuration
6 Amp
Output 1
Engine
Start or
Trolling
6 Amp
Output 2
Model12 Amp
16102(6/6)
SA F E M O D E

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Diagram 5 – 16153 in a triple Independent Output configuration
SAFE M OD E
18 Amp
(6/6/6)
6 Amp
Output 1
Engine
Start or
Trolling
6 Amp
Output 2
6 Amp
Output 3

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Diagram 6 – 16153 in a 36VDC, 6Amp configuration
SAFE M OD E
18 Amp
(6/6/6)
6 Amp
Output 1
Engine
Start or
Trolling
6 Amp
Output 2
6 Amp
Output 3

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Diagram 7 – 16153 in a 12VDC, 6Amp and 24VDC, 6Amp configuration
SAFE M OD E
18 Amp
(6/6/6)
6 Amp
Output 1
Engine
Start or
Trolling
6 Amp
Output 2
6 Amp
Output 3

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Diagram 8 – 16153 in a 12VDC, 6Amp and 12VDC, 12Amp configuration
SAFE M OD E
18 Amp
(6/6/6)
6 Amp
Output 1
Engine
Start or
Trolling
6 Amp
Output 2
6 Amp
Output 3

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Diagram 9 – 16153 in a 12VDC, 18Amp configuration
SAFE M OD E
18 Amp
(6/6/6)
6 Amp
Output 1
Engine
Start or
Trolling
6 Amp
Output 2
6 Amp
Output 3

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Diagram 10 – 16202 in a dual Independent Output configuration
10 Amp
Output 1
Engine
Start or
Trolling
10 Amp
Output 2

17
Diagram 11 – 16202 in a 24VDC, 10Amp configuration
10 Amp
Output 1
Engine
Start or
Trolling
10 Amp
Output 2

18
Diagram 12 – 16202 in a 12VDC, 20Amp configuration
10 Amp
Output 1
Engine
Start or
Trolling
10 Amp
Output 2

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OPERATIN THE CHAR ER
The LED Function Chart below describes the charging process for both the 6amp and 10amp
charger models.
Charger
Status LED
Display
Operating condition
ED
When the red LED is on, it indicates that your battery is discharged and the
battery charger is recharging the battery at the "Bulk" rate (stage 1). This
charging rate is approximately 6 to 10Amps depending on specific charger
model.
While the red LED is on, the battery charger will provide the maximum
charger current rating until the battery voltage reached the maximum bulk
voltage for the selected battery chemistry according to Table 1.
If an excessive amount of time is taken to complete this stage, the charger will
time out and present a fault indicator. (see Troubleshooting Section.)
BLUE
When the blue LED is on, it is charging at the “absorption” rate. (Stage 2).
During this second charging stage, the charger holds the battery voltage at
the specified battery chemistry absorption stage voltage according to Table 1
and gradually reduces the amount of current delivered to the battery.
If an excessive amount of time is taken to complete this stage, the charger will
time out and automatically transition into the “float” stage.
The Intelligent Charging System Series uses the internal micro-controlled
timers to transition the charger output voltage from absorption stage to float
stage to protect the battery from electrolyte depletion. In the float stage the
charger can still supply full output current to battery and external loads.
G EEN
When the green LED is on, the charge cycle is completed and the battery is
ready for use. The optimum replenishment of charge has been returned to
the battery.
The charger will regulate the battery at the nominal float stage voltage
specified in Table 1.
The charger will be able to supply maximum charger output current during this
stage for external DC loads. External DC loads may cause the regulated
voltage to drop, if the battery voltage falls below approximately 12.6VDC, the
charger will automatically restart the charge process.

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Table 1 - Charger Stage Approximate Voltage Specifications
Based on Battery Chemistry Selected
3-Battery Chemistry Selections
Stage 3-Stage
Algorithm
Flooded Lead
Acid (FLA)/AGM
GEL Safe Mode *
1 Bulk
Stage**
14.4VDC 14.1VDC 14.0VDC
2 Absorption
Stage
14.4VDC 14.1VDC 14.0VDC
3 Float
Stage
13.5VDC 13.8VDC 13.4VDC
*The safe mode algorithm was developed for the individual who is unable to identify their
battery chemistry or application needs.
**The charger bulk stage voltages may vary based on the voltage drops across the DC
cable
Battery Fault Indication
The blinking red LED of the respective Charge Status LED will serve as the fault
indicator. Fault indication is defined as follows:
Charge Status RED LED Indication
1 X Blink No Battery Present
3 X Blink 14hr. Bulk Stage Timer has Expired
5 X Blink Corrupt program memory